Segmented Piston Bolt Passages for Easier Shock Absorber Machining
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Solution Overview
Problem
The existing shock absorber designs face challenges in precision processing due to the need for specialized tools and methods to form the common passage, leading to increased man-hours, manufacturing costs, and reduced productivity.
Innovation Solution
The shock absorber design incorporates a piston bolt formed by two divided members, allowing for the formation of different diameter passages using general-purpose tools, facilitating easier processing and reducing man-hours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a common passage is formed by inserting a tool from the head portion in one direction, then the passage can be processed, but it necessitates a special method and tool to process the large-diameter portion on the deep side, making it difficult to ensure precision
Solution Approach 1:
The piston bolt is divided into two separate members: a first member (body portion) and a second member (shaft portion). The common passage is formed in the first member using general-purpose tools from an easily accessible direction, while the second member is separately processed and then assembled to the first member. This segmentation eliminates the need for complex deep-hole processing tools and methods, ensuring both manufacturing ease and precision.
Solution Approach 2:
Instead of forming the common passage by inserting a tool from the head portion (front side) in one direction as in conventional designs, the invention forms the passage in the body portion by inserting a tool from the opposite direction (rear side). This inversion of the processing direction allows the use of general-purpose tools and simplifies the manufacturing process while maintaining precision.
2Ease of manufacture
If a common passage is formed by inserting a tool from the front side in one direction, then the passage can be processed, but it leads to an increase in man-hours and thus an increase in the manufacturing cost
Solution Approach 1:
By dividing the piston bolt into two members and forming the common passage in the first member using standard tools, the processing can be completed more efficiently without requiring specialized deep-hole processing equipment. This reduces the complexity of the manufacturing process and decreases the man-hours required.
Solution Approach 2:
The invention inverts the conventional processing approach by forming the common passage from the rear side instead of the front side. This allows the use of general-purpose tools that are already available in standard workshops, eliminating the need for special tools and methods, thereby reducing manufacturing time and costs.
3Ease of manufacture
If a common passage is formed by inserting a tool from the front side in one direction, then the passage can be processed, but it serves as a cause for a reduction in the productivity
Solution Approach 1:
The piston bolt is segmented into two members, with the common passage formed in the first member using simple, standard processing methods. This eliminates the need for complex, time-consuming deep-hole processing operations, thereby increasing production efficiency and productivity.
Solution Approach 2:
The processing direction is inverted from the conventional front-side approach to a rear-side approach. This allows the use of general-purpose tools and simplifies the processing steps, reducing manufacturing time and improving overall productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces man-hours for processing the piston bolt, improves productivity, and lowers manufacturing costs by enabling more precise and efficient formation of the common passage.
Implementation Method 1
a valve spring configured to bias the valve shaft in a valve-opening direction
Implementation Method 2
a common passage configured to establish communication between the extension-side backpressure chamber and the compression-side backpressure chamber
Data Source
AI summary
A piston bolt is formed by divided first and second members, and a first small-diameter portion and a large diameter portion of a common passage are formed in the first member and a second small-diameter portion of the common passage is formed in the second member. This configuration allows the common passage to be processed using a general-purpose method and tool and contributes to reducing the man-hours for the piston bolt.